Coolant pump - removal and refitting
OHV engine
Removal
1 Drain the cooling system.
2 Release the coolant pump pulley bolts now while the drivebelt is still in position. Any tendency for the pulley to turn as the bolts are unscrewed can be restrained by depressing the top run of the belt.
3 Release the alternator mounting and adjuster link bolts, push the alternator in towards the engine and slip the drivebelt from the coolant pump pulley.
4 Disconnect the coolant hose from the pump. Remove the previously slackened pulley bolts and take off the pulley.
5 Unbolt the coolant pump and remove it.
6 Peel away the old gasket from the engine block and clean the surface.
7 No provision is made for repair and if the pump is leaking or noisy it should be renewed.
Refitting
8 Refitting is a reversal of removal. Use a new gasket, smeared with jointing compound, and apply the same compound to the threads of the fixing bolts. Tighten the bolts to the specified torque.
9 Adjust the drivebelt tension and refill the cooling system.
CVH engine
Removal
10 Drain the cooling system.
11 Release the alternator mountings and adjuster strap bolt, push the alternator in towards the engine and slip the drivebelt from the pulley.
12 Apply a spanner to the crankshaft pulley bolt and turn the crankshaft until the notch on the pulley is opposite the TDC mark on the belt cover scale.
Timing marks - CVH
13 Remove the timing belt cover. Note that on engines fitted with the later type two-piece cover, it is not possible to remove the cover lower half unless the crankshaft pulley is removed first. However, if the two lower cover retaining bolts are removed, the cover can be moved away from the engine sufficiently for the pump to be removed and refitted with the cover still in place.
14 Check that the camshaft and the crankshaft sprockets are aligned with their timing marks. This will prove that No 1 piston is at top dead centre, not No 4 piston. If the marks are not aligned, turn the crankshaft through another complete turn.
15 Using a spot of quick-drying paint, mark the teeth of the belt and their notches on the sprockets so that the belt can be re-engaged in its original position in relation to the sprocket teeth.
16 Slacken the belt tensioner bolts
Slacken the timing belt tensioner bolts (arrowed)
and slide the tensioner to relieve the tautness of the belt, then slip the belt from the crankshaft sprocket tensioner pulley and the coolant pump sprocket.
17 Release the clamps and disconnect the hoses from the coolant pump.
18 Remove the timing belt tensioner.
19 Unscrew the four bolts and remove the coolant pump from the engine cylinder block.
Coolant pump unit retaining bolts (arrowed)
20 No provision is made for repair and if the pump is leaking or noisy it must be renewed.
Refitting
21 Clean away the old gasket and ensure that the mating surfaces of the pump and block are perfectly clean.
22 Position a new gasket (on the cylinder block) which has been smeared both sides with jointing compound. Offer up the coolant pump, screw in the bolts and tighten to the specified torque.
23 Fit the belt tensioner, but with the mounting bolts only screwed in loosely.
24 Reconnect and tension the timing belt.
25 Refit the timing belt cover.
26 Fit the alternator drivebelt and tension it.
27 Reconnect the coolant hoses to the pump and the bottom hose to the radiator.
28 Fill the cooling system.